Modular foam bed

ABSTRACT

Some embodiments of the invention include a modular foam bed comprising a foam base layer having a length and a width; a foam edge support having a length that is substantially the same as the length of the foam base layer and a width that is substantially the same as the width of the foam base layer, the foam edge support comprising a cavity; a first support layer sized and configured to be disposed within the cavity of the foam edge support; a second support layer sized and configured to be disposed within the cavity of the first foam edge support adjacent with the first support layer; and a foam top layer having a length that is substantially the same as the length of the foam base layer and a width that is substantially the same as the width of the foam base layer.

BACKGROUND

Sleep is a necessity. Good sleep is a gift. Various factors may be the difference between okay sleep and good sleep. Beds, in particular, may greatly impact a person's sleep quality. In addition, individuals differ on the type and/or characteristics of a bed that can provide the quality of sleep needed for each individual. Typical foam beds are static: the density and/or hardness and/or softness cannot be changed over time or at different portions of the bed.

SUMMARY

Some embodiments of the invention include a modular foam bed comprising a foam base layer having a length and a width; a foam edge support having a length that is substantially the same as the length of the foam base layer and a width that is substantially the same as the width of the foam base layer, the foam edge support comprising a cavity; a first support layer sized and configured to be disposed within the cavity of the foam edge support; a second support layer sized and configured to be disposed within the cavity of the first foam edge support adjacent with the first support layer; and a foam top layer having a length that is substantially the same as the length of the foam base layer and a width that is substantially the same as the width of the foam base layer.

In some embodiments, the modular foam bed may include a fire barrier.

In some embodiments, the modular foam bed may include a fabric cover surrounding the foam base layer, the foam edge rail, the first support layer, the second support layer, and foam top layer.

In some embodiments, the modular foam bed may include a third support layer disposed within the cavity on the foam base layer; and a fourth support layer disposed within the cavity on the third support layer.

In some embodiments, the combined thickness of the first support layer and the second support layer is greater than the thickness of the edge support layer.

In some embodiments, the combined thickness of the first support layer and the second support layer is about the same as the thickness of the edge support layer.

In some embodiments, the base layer comprises a foam that has a density of 1.3 to 2.3 lb/ft³.

In some embodiments, the base layer comprises a 24 ILD to 38 ILD foam. In some embodiments, the first support layer comprises a foam selected from the group consisting of a 1.5-2.5 lb./ft³, 14 ILD foam, 1.5-2.5 lb./ft³, 22 ILD foam, and a 1.5-2.5 lb./ft³, 35 ILD foam. In some embodiments, the second support layer comprises a foam selected from the group consisting of a 1.5-2.5 lb./ft³, 14 ILD foam, 1.5-2.5 lb./ft³, 22 ILD foam, and a 1.5-2.5 lb./ft³, 35 ILD foam.

In some embodiments, first support layer and/or the second support layer comprises a foam that has a density of 1.5 to 3.5 lb./ft³. In some embodiments, the first support layer and/or the second support layer comprises a 8 ILD to 15 ILD foam. In some embodiments, the first support layer and/or the second support layer comprises a foam that has a density of 1.5-2.5 lb./ft³. In some embodiments, the first support layer and/or the second support layer comprises an 16 ILD to 24 ILD foam. In some embodiments, the first support layer and/or the second support layer comprises a 25 ILD to 40 ILD foam.

In some embodiments, the first support layer and/or the second support layer have different foam densities.

In some embodiments, the first support layer and/or the second support layer have different ILD values.

In some embodiments, the top layer comprises a dual zone phase change gel memory foam. In some embodiments, the top layer comprises a quick recovery foam. In some embodiments, the top layer comprises heat wicking properties.

BRIEF DESCRIPTION OF THE FIGURES

These and other features, aspects, and advantages of the present disclosure are better understood when the following Detailed Description is read with reference to the accompanying drawings.

FIG. 1 illustrates a modular foam bed.

FIG. 2 illustrates a base layer of a modular foam bed.

FIG. 3 illustrates a base layer and edge support of a modular foam bed.

FIG. 4 illustrates a first support layer and a second support layer disposed side-by-side within different portions of the cavity of the edge support.

FIG. 5 illustrates a first support layer and a second support layer disposed side-by-side within different halves of the cavity of the edge support.

FIG. 6 illustrates a first support layer and a second support layer disposed side-by-side within different halves of the cavity of the edge support.

FIG. 7 illustrates a first support layer and a second support layer disposed within different halves of the cavity of the edge support.

FIG. 8 illustrates a first support layer and a second support layer disposed within different halves of the cavity of the edge support.

FIG. 9 illustrates the fourth support layer disposed on the base layer; and the second support layer disposed on the fourth support layer within the cavity of the edge support.

FIG. 10 illustrates the third layer disposed on the base layer; and the first support layer disposed on the third layer within the cavity of the edge support.

FIG. 11 illustrates a top layer disposed on the edge support. The top layer may also be disposed on the first support layer and/or the second support layer disposed within the cavity.

FIG. 12 illustrates a modular foam bed disposed within a fire barrier.

DETAILED DESCRIPTION

A modular foam bed is disclosed. In some embodiments, the modular foam bed may include a base foam layer, edge support disposed on the base foam layer, a plurality of support layers, and/or a top layer. In some embodiments, the modular foam bed may also include a fire barrier and/or a bed cover.

In some embodiments, the base foam layer may comprise a foam with a density of 1.0 to 3.5 lb./ft³. In some embodiments, the base foam layer may be a 20 ILD to 45 ILD foam. In some embodiments, the base foam layer may comprise a foam with a density of 1.3 to 2.3 lb./ft³. In some embodiments, the base foam layer may be a 30 ILD to 40 ILD foam; for example, a 35 ILD foam. In some embodiments, the base foam layer may have a thickness of 2″ to “ to 6”. The base foam layer may include any type of foam material. For example, the base foam layer may include a 1.8 lb./ft³, 35 ILD foam.

Indentation Force Deflection (“ILD”) (also referred to as Indentation Load Deflection) represents the amount of weight or pressure required to press a 50 square inch indentation one inch into a four inch piece of foam. Thus, a foam with a 32 ILD requires 32 pounds to press a 50 square inch indentation 1 inch into a 4 inch piece of the foam.

In some embodiments, the edge support may include a foam having a density of 1.0 to 3.0 lb./ft³. In some embodiments, the edge support may include a 20 ILD to 50 ILD foam. In some embodiments, the edge support may include a foam having a density of 1.2 to 2.4 lb./ft³. In some embodiments, the edge support may include a 30 ILD to 44 ILD foam.

In some embodiments, the edge support may include a 1.8 lb./ft³, 36 ILD foam. In some embodiments, the edge support may have a thickness of 3.0 to 4.5 inches. For example, the edge support may have a thickness of 3.75 inches.

In some embodiments, the edge support may include two side support rails and two end support rails (e.g., head and foot of the bed) coupled together. The edge support may form a rectangular shape with an internal cavity or space bounded by the edge support. In some embodiments, side support rails and the end support rails may be joined, fastened, coupled, sewn, or glued together to form a rectangular shape with an internal cavity. Alternatively, the edge support may be formed as a single composite member. The side support rails and the end support rails, for example, may have the dimensions in the following chart.

Bed Size Rails Thickness Width Length Twin ends 3.75 6 38 Twin sides 3.75 5 62 Twin XL ends 3.75 6 38 Twin XL sides 3.75 5 68 Full ends 3.75 6 53 Full sides 3.75 5 62 Queen ends 3.75 6 60 Queen sides 3.75 5 68 Cal King ends 3.75 6 72 Cal King sides 3.75 5 72 Eastern King ends 3.75 6 76 Eastern King sides 3.75 5 68

While the sized in the chart can be used, any thickness, width, and/or length may be use.

In some embodiments, the plurality of support layers may include a plurality of different foam support layers such as, for example, having different densities and/or different ILD values. For example, the plurality of support layers may include one or more of a soft support layer, a medium support layer, and/or a firm support layer. In some embodiments, any combination of two different or the same support layer may be included. For example, a modular foam bed may include two soft support layers, one soft support layer and one medium support layer, one medium support layer and one firm support layer, one soft support layer and one firm support layer, etc. placed on top of the other.

In some embodiments, the soft support layer may have a density of 1.5-4.0 lb./ft³. In some embodiments, the soft support layer may be a 6 ILD to 22 ILD foam. In some embodiments, the soft support layer may have a density of 1.5 to 2.0 lb./ft³. In some embodiments, the soft support layer may be a 10 ILD to 20 ILD foam. The soft support layer, for example, may include a 1.8 lb./ft³, 14 ILD or 18 ILD foam.

In some embodiments, the medium support layer may have a density of 1.5-4.0 lb./ft³. In some embodiments, the medium support layer may be a 10 ILD to 34 ILD foam. In some embodiments, the medium support layer may have a density of 1.5 to 2.0 lb./ft³. In some embodiments, the medium support layer may be a 20 ILD to 30 ILD foam. The medium support layer, for example, may include a 18 lb./ft³, 24 ILD foam.

In some embodiments, the firm support layer may have a density of 1.5-4.5 lb./ft³. In some embodiments, the firm support layer may be a 20 ILD to 50 ILD foam. In some embodiments, the firm support layer may have a density of 1.5-2.5 lb./ft³. In some embodiments, the firm support layer may be a 28 ILD to 42 ILD foam. The firm support layer, for example, may include a 1.8 lb./ft³, 35 ILD foam.

In some embodiments, each of the plurality of support layers may have a thickness that is greater than or equal to half the thickness of the edge support.

In some embodiments, a twin-, twin XL-, or full-sized modular foam bed may include a stack of two support layers disposed within a single cavity. In some embodiments, a queen- or king-sized modular foam bed may include two side-by-side stacks of two support layers disposed within the cavity. In some embodiments, the edge support may be disposed on the base layer surrounding the plurality of support layers.

In some embodiments, the top foam layer comprises a dual zone phase change gel memory foam. In some embodiments, the top foam layer comprises a quick recovery memory foam. In some embodiments, the top foam layer comprises a heat wicking material. In some embodiments, the top foam layer may be disposed on the edge support, and/or the plurality of support layers.

In some embodiments, the top foam layer may have a density of 1.5-4.0 lb./ft³. In some embodiments, the top foam layer may be a 8 ILD to 15 ILD foam. In some embodiments, the top foam layer may have a density of 3 to 5 lb./ft³. In some embodiments, the top foam layer may be a 10 ILD to 20 ILD foam. In some embodiments, the top foam layer may have a density of 1.5-5 lb./ft³. In some embodiments, the top foam layer may be a 25 ILD to 40 ILD foam.

In some embodiments, the top foam layer may have a thickness of 1 to 3 inches. For example, the top foam layer may have a thickness of 2 inches. The top foam layer may include any type of foam material. For example, the top foam layer may include a 4 lb./ft³, 10 ILD foam. In some embodiments, the top foam layer may be disposed on the plurality of support layers and/or the edge support.

In some embodiments, the fire barrier may include a fireproof material such as, for example, a glass fiber material and/or may have a 180 gram weight and/or may have 6 ounces per square yard. Any type of fire barrier material may be used.

In some embodiments, the bed cover may include a fabric material that that surrounds the top foam layer, the plurality of support layers, the edge support, and the base foam layer. In some embodiments, the bed cover may include a zipper that allows a user to remove one or more layers of the modular foam bed. For instance, the user may replace one type of the plurality of support layers with a different type of the plurality of support layers. The zipper, for example, may located in the cording or pillow top cording seam of the bed cover. As another example, the zipper may be located along the side of the bed cover (relative to the modular foam bed). For example, the zipper may be located about 2″, 2.5″, 3″, 3.5″, 4″, etc. from the top or bottom of the bed cover.

FIG. 1 illustrates a modular foam bed 100.

FIG. 2 illustrates a base layer 110 of a modular foam bed.

FIG. 3 illustrates a base layer 110 and edge support 120 of a modular foam bed. The edge support 120 is disposed on the base layer 110. The edge support 120 includes cavity 121. The edge support 120 may, for example, have a width that is substantially similar to the width of the base layer 110. The edge support 120 may, for example, have a length that is substantially similar to the length of the base layer 110.

FIG. 4 illustrates a first support layer 130 and a second support layer 135 disposed side-by-side within different portions of the cavity 121 of the edge support 120. In this example, the first support layer 130 and the second support layer 135 may or may not have different foam densities and/or different ILD values. The first support layer 130 and the second support layer 135, for example, may have a length that is substantially the same as or slightly less than the internal length of the cavity 121. The first support layer 130 and the second support layer 135, for example, may have a width that is substantially the same as or slightly less than half the internal width of the cavity 121.

FIG. 5 illustrates a first support layer 130 and a second support layer 135 disposed side-by-side within different halves of the cavity 121 of the edge support 120. In this example, the first support layer 130 and the second support layer 135 may or may not have different foam densities and/or different ILD values.

FIG. 6 illustrates a first support layer 130 and a second support layer 135 disposed side-by-side within different halves of the cavity 121 of the edge support 120. In this example, the first support layer 130 and the second support layer 135 may or may not have different foam densities and/or different ILD values.

FIG. 7 illustrates a first support layer 130 and a second support layer 135 disposed within different halves of the cavity 121 of the edge support 120. A third support layer 131 is disposed within the cavity 121 between the first support layer 130 and the base layer 110. In this example, the first support layer 130, the second support layer 135, and the third support layer 131 may or may not have different foam densities and/or different ILD values. The third support layer 131, for example, may have a length that is substantially the same as or slightly less than the internal length of the cavity 121. The third support layer 131, for example, may have a width that is substantially the same as or slightly less than half the internal width of the cavity 121.

FIG. 8 illustrates a first support layer 130 and a second support layer 135 disposed within different halves of the cavity 121 of the edge support 120. A third support layer 131 is disposed within the cavity 121 between the first support layer 130 and the base layer 110. A fourth support layer 136 is disposed within the cavity 121 below the second support layer 135 and disposed on the base layer 110. In this example, the first support layer 130, the second support layer 135, the third support layer 131, and the fourth support layer 136 may or may not have different foam densities and/or different ILD values. The third support layer 131 and the fourth support layer 136, for example, may have a length that is substantially the same as or slightly less than the internal length of the cavity 121. The third support layer 131 and the fourth support layer 136, for example, may have a width that is substantially the same as or slightly less than half the internal width of the cavity 121.

FIG. 9 illustrates the fourth support layer 136 disposed on the base layer; and the second support layer 135 disposed on the fourth support layer 136 within the cavity 121 of the edge support 120.

FIG. 10 illustrates the third support layer 131 disposed on the base layer; and the first support layer 130 disposed on the third support layer 131 within the cavity 121 of the edge support 120.

FIG. 11 illustrates a top layer 155 disposed on the edge support 120. The top layer 155 may also be disposed on the first support layer 130 and/or the second support layer 135 disposed within the cavity 121.

FIG. 12 illustrates a modular foam bed disposed within a fire barrier 160.

Unless otherwise specified, the term “substantially” means within 5% or 10% of the value referred to or within manufacturing tolerances. Unless otherwise specified, the term “about” means within 5% or 10% of the value referred to or within manufacturing tolerances.

Numerous specific details are set forth in this document to provide a thorough understanding of the claimed subject matter. However, those skilled in the art will understand that the claimed subject matter may be practiced without these specific details. In other instances, methods, apparatuses or systems that would be known by one of ordinary skill have not been described in detail so as not to obscure claimed subject matter.

The use of “adapted to” or “configured to” herein is meant as open and inclusive language that does not foreclose devices adapted to or configured to perform additional tasks or steps. Additionally, the use of “based on” is meant to be open and inclusive, in that a process, step, calculation, or other action “based on” one or more recited conditions or values may, in practice, be based on additional conditions or values beyond those recited. Headings, lists, and numbering included herein are for ease of explanation only and are not meant to be limiting.

While the present subject matter has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, it should be understood that the present disclosure has been presented for purposes of example rather than limitation, and does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art. 

That which is claimed:
 1. A modular foam bed comprising: a foam base layer having a length and a width; a foam edge support having a length that is substantially the same as the length of the foam base layer and a width that is substantially the same as the width of the foam base layer, the foam edge support comprising a cavity; a first support layer sized and configured to be disposed within the cavity of the foam edge support and comprising a foam having a first ILD value; a second support layer sized and configured to be disposed within the cavity of the first foam edge support on top of the first support layer and comprising a foam having a second ILD value; and a foam top layer having a length that is substantially the same as the length of the foam base layer and a width that is substantially the same as the width of the foam base layer.
 2. The modular foam bed according to claim 1, wherein the first ILD value is different than the second ILD value.
 3. The modular foam bed according to claim 1, further comprising a fabric cover surrounding the foam base layer, the foam edge rail, the first support layer, the second support layer, and foam top layer.
 4. The modular foam bed according to claim 1, further comprising a third support layer disposed within the cavity on the foam base layer; and a fourth support layer disposed within the cavity on the third support layer.
 5. The modular foam bed according to claim 1, wherein the combined thickness of the first support layer and the second support layer is greater than the thickness of the edge support layer.
 6. The modular foam bed according to claim 1, wherein the combined thickness of the first support layer and the second support layer is about the same as the thickness of the edge support layer.
 7. The modular foam bed according to claim 1, wherein the base layer comprises a foam that has a density of 1.3 to 2.3 lb./ft³.
 8. The modular foam bed according to claim 1, wherein the base layer comprises a 24 ILD to 38 ILD foam.
 9. The modular foam bed according to claim 1, wherein the first support layer and/or the second support layer comprises a foam selected from the group consisting of 10-20 ILD foam, 20-30 ILD foam, and a 30-40 ILD foam.
 10. The modular foam bed according to claim 1, wherein the first support layer and/or the second support layer comprise a density of 1.5-2.0 lb./ft³.
 11. The modular foam bed according to claim 1, wherein the first support layer and/or the second support layer comprises a foam that has a density of 2.5-3.5 lb./ft³.
 12. The modular foam bed according to claim 1, wherein the first support layer and/or the second support layer comprises a 10 ILD to 20 ILD foam.
 13. The modular foam bed according to claim 1, wherein the first support layer and/or the second support layer comprises a foam that has a density of 1.5 to 3.0 lb./ft³.
 14. The modular foam bed according to claim 1, wherein the first support layer and/or the second support layer comprises an 20 ILD to 30 ILD foam.
 15. The modular foam bed according to claim 1, wherein the first support layer and/or the second support layer comprises a 30 ILD to 40 ILD foam.
 16. The modular foam bed according to claim 1, wherein the first support layer and/or the second support layer have different foam densities.
 17. The modular foam bed according to claim 1, wherein the first support layer and/or the second support layer have different ILD values.
 18. The modular foam bed according to claim 1, wherein the top layer comprises a dual zone phase change gel memory foam.
 19. The modular foam bed according to claim 1, wherein the top layer comprises a quick recovery foam.
 20. The modular foam bed according to claim 1, wherein the top layer comprises heat wicking properties. 